A written report should be prepared when the inspection is finished. If replacement

parts are needed as a result of the inspection, these parts should meet the original part’s

specification.

If a crane has been damaged and there are risks to health and safety, it should be

immediately taken out of service and people prevented from operating the crane. If the

crane needs to be operating during maintenance or cleaning, risk control measures must

enable this to occur without risk to health and safety.

Annual inspection

Regular inspections must be carried out in accordance with the manufacturer’s instructions

or those of a competent person or, if this is not reasonably practicable, annually.

An annual inspection may be less comprehensive than a major inspection. It should include

every item specified by the crane manufacturer for annual inspection and every item

included in the routine inspection and maintenance programs.

Annual inspections should include a detailed check of:

unctioning and calibration of limiting and indicating devices

structural and wear components

tolerances for wear limit

evidence of corrosion

critical areas for evidence of cracking, and

for tower cranes, relevant items in the pre-erection inspection and tests that can be safely completed while the crane is erected

Where a tower crane owner is aware a crane will be erected when the scheduled annual

inspection falls due, the owner can choose to carry out an annual inspection before

erecting the crane or during the pre-erection inspection

Major inspections

A major inspection must be completed for registered mobile and tower cranes.

Non-registrable mobile cranes and bridge and gantry cranes should have a regular ‘major’

inspection completed so that they continue to be safe to operate.

Major inspections must be carried out at the end of the crane’s design life, as determined

by the manufacturer’s instructions, or if these are not available, as determined by a

competent person to meet the same minimum requirements established by relevant

technical standards.

If it is not reasonably practicable to inspect a crane according to either of these, you

should inspect the crane at least every 10 years from the date the crane was first

commissioned or registered, whichever was first. This must include inspection of the

structure as well as mechanical components.

Major inspections must be carried out by, or under the supervision of, a competent person

who:

has acquired through training, qualifications or experience the knowledge and skills to carry out a major inspection of the plant and is registered under a law that provides for the registration of professional engineers, or

is determined by the regulator to be a competent person.

Appendix A lists some items to be inspected during a major inspection for tower and

mobile cranes. Some of the items may not apply, for example where the item does not

exist on the crane. The full list of items to be inspected must be determined by a

competent person.

Completion of a major inspection does not indicate that the components inspected will

have a further 10 year life. It should not be assumed that the items included in the list

only require inspection at 10 yearly intervals. Items will require some type of inspection

and maintenance at more frequent intervals, for example at annual and other inspection

intervals, according to the crane manufacturer’s instructions.

Where there is documented evidence that inspection and testing has been carried out

a reasonable preceding period (as determined by a competent person) the item may

not have to be stripped down in the major inspection. The competent person should still

inspect the safe operation of the item to certify it is operating safely and document the

reasons for the decision.

Record keeping

Crane records including maintenance logbooks of the significant events concerning

the safety and operation of the crane must be kept and readily available. Records

should be kept in a suitable format and must be transferred with ownership of the

crane. Entries in the maintenance logbook should

clearly describe the work carried out and parts replaced

be dated

note the name of the person carrying out the work, and

be signed by the person carrying out the work.

The checks, adjustments, replacement of parts, repairs, inspections performed and

irregularities or damage concerning the unit’s safe use must be recorded.

Inspection records should include a statement from a competent person confirming

the item of plant has been inspected and is safe to operate.

Inspection records should include

What was looked at – component specification or areas of the plant inspected.

What was looked for – signs of wear, damage, cracking or corrosion.

What criteria were used – rejection criteria.

How was it looked for – techniques used.

What was found – test results, photographs or measurement.

What was recommended – repairs required before continued use.

What recommendations were actioned – recommendations acted upon and date

tasks were completed.

Tower cranes

Pre-erection inspection and tests—on ground inspection

Tower crane components should be inspected and tested by a competent person

according to the manufacturer’s instructions before being delivered to the workplace

and before being erected.

Where a tower crane owner is aware a crane will be erected when the scheduled annual

inspection is due, the owner may consider carrying out an annual inspection during the

pre-erection inspection.

Crane owners should develop their own pre-erection inspection and test report that

satisfies the requirements of the WHS Regulations and the manufacturer’s instructions.

The report should also reflect the specific type and model of crane and reference relevant

design drawings and test certificates.

Commissioning inspection and tests

Commissioning inspections and test should be carried out by a competent person

according to the manufacturer’s instructions before a tower crane is put into service.

Non-destructive testing of tower crane components

Non-destructive testing (NDT) is the testing of materials to detect internal, surface and

concealed defects, cracks, breaks or gaps using methods which do not damage or destroy

the material being tested.

NDT must be carried out by a competent person having suitable knowledge and

experience in NDT methods and being able to determine the appropriate NDT method for

the component being tested.

When using magnetic particle NDT to detect cracks in metals remove the paint from the

metal surface. This is not required for Eddy current NDT.

NDT of specific tower crane components should take place according to the

manufacturer’s instructions and at set intervals, for example pre-erection tests and major

inspection. Table 1 indicates some common minimum frequencies of NDT for particular

crane components.

Table 1. Minimum frequency of NDT for particular crane components

Component tested

NDT description

NDT frequency

Boom clevises

Crack test

Pre-erection

Counterweight sheave bracket welds – moving
counterweights only

Crack test

Pre-erection

Cruciform welds – luffing cranes onl

Crack test

Pre-erection

Butt heal bosses – luffing cranes onl

Crack test

Pre-erection

Band brake welds

Crack test

Pre-erection

Slew ring bolts – where slew ring has to be
split at disassembl

Crack test minimum 10% bolts

Pre-erection

Tower bolts (where applicable

Crack test minimum 10%

Pre-erection

Boom lacing welds

Crack test minimum 10%

Pre-erection

Tower sections

Crack test minimum 10%

Pre-erection

Aluminium sheaves

Crack test

Pre-erection

Slew ring bolts – slew ring

Crack test bolts

5 years

Boom chord thickness

Material thickness testing

10 years

Slew ring

Crack test

10 years

Hydraulic luffing cylinder gland nut

Crack test

10 years

Hydraulic luffing cylinder and ram-rod ends
and caps

Crack test

10 years

A-frame – connector welds on primary chords

Crack test

10 years

A-frame lacing welds

Crack test

10 years

Hook

Crack test

10 years

Welds on hook trolley

Crack test

10 years

Crack testing of booms and counterweight sheave bracket welds

Booms on non-self-erecting tower cranes are connected by pins passing through male and
female clevises on the ends of each boom section. Every weld on male and female clevises
on the ends of every boom section should undergo NDT before each crane erection for
non-self-erecting cranes. Magnetic particle testing is the usual method
used for performing these tests.

Counterweight sheave bracket welds, butt heal bosses and welds in cruciform area on
luffing crane booms are known to crack and should also be crack tested by NDT before
each crane erection.

Crack testing of band brakes

Older designs of luffing tower cranes use band brakes. On some of these cranes the steel
band is welded to an end fitting that has a pin passing through it. These welds have been
known to crack.

You should crack test the weld between the band and the end fitting by NDT before each
time a luffing tower crane fitted with band brakes is erected, keeping in mind there may
not be a weld on some brake bands.

Crack testing of slew ring bolts

The integrity of slew ring bolts is critical for making sure both the machine deck and boom
remain attached to the tower. Once removed, slew ring bolts should be replaced unless the
manufacturer’s instructions state they can be reused. If bolts can be reused they should be
tested.
For tower cranes where the slew ring needs to be split each time the crane is moved,
NDT 10 per cent of slew ring bolts is suggested. Bolts to be tested should be selected from the slew
ring by a competent person. Complete removal of the bolts from the slew ring and use
of magnetic particle testing is recommended. If cracks are detected, bolts should be
discarded and replaced with new bolts.

Crack testing of tower bolts or pins

Tower bolts or pins are a critical part of the crane and permit the effective transfer of load
from the crane boom to the crane base. Tower bolts or pins can become damaged and
their effective life can be reduced if the bolts are either under or over-torqued. Some tower
bolts are made from extremely high grade steel and can be more susceptible to cracking.

Unless the manufacturer’s instructions state tower bolts can be reused, they should be
replaced. If bolts can be reused, crack test a minimum of 10 per cent of tower bolts by
NDT before each crane erection. If cracks are found, tower bolts should be discarded and
replaced with new bolts.

A system that makes sure tower bolts or pins are tested over time is preferred. However
a random system of testing can also be used. The tested bolts should be identified by
a method that does not damage the bolt.

Chord thickness testing

Steel lattice-type tower crane booms can be prone to internal and external corrosion
affecting the thickness of the boom. The thickness of the chord wall can be reduced
through abrasive blasting of the boom.

Main chord sections on tower crane booms should undergo thickness testing at intervals
not exceeding 10 years. Ultrasonic thickness testing is one method of verifying the strength
in the chords of the boom.

Review chord sections for structural adequacy when the thickness is shown by testing
to be 90 per cent or less than 90 per cent of the original thickness.
Further information

The following technical standards provide further information on inspecting and
maintaining cranes:

AS 2550.1-2011: Cranes, hoists and winches—Safe use Part 1: General requirements

The condition of ropes and sheaves e.g.
erecting, hoisting, counterweight and
trolley, correct rope tracking and no
signs of damage or excess wea

The condition of limit switches and
limiting devices

The condition of counterweights

The condition and fitment of machinery
guarding

Brake systems can be dismantled and
inspected for wear and damage

dry brakes—before each erection or
more frequently if directed by the
manufacturer

wet brakes—before each erection or
after 5 000 hours of crane operation
or as directed by the manufacturer

Normal service items including items
supplied by the crane manufacturer e.g.
temperature control units and seating
being maintained in a serviceable
condition according to the crane
manufacturer’s instructions, and

Other tests as specified by the
manufacturer.

Once the tower crane components have
been delivered to the workplace they
should be inspected by a competent
person for possible damage and
wear that may have occurred during
transport. Inspections should include:

The crane base design and engineer’s
repor

Crane ties and structure to support
them where used

The power supply and earthing

Crane electricity supply—where used

Crane base weights or ballast—where
used

Tower section identification and
entry

Tower bolts to correct tension

Pins and fastenings

Climbing frame and connection

Jib connection pins and retainers

A-frame connections and retainers—
where applicable

Jib and deck pendant pins and
retainers—where used

Machinery guarding

Leakage in lines, tanks, valves, pumps
and other parts of air or hydraulic
systems

The condition of the ropes and
sheaves e.g. erecting, hoisting, trolley
and counterweight, and correct rope
tracking